Professional Documents
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Manual de Servicio Nissan
Manual de Servicio Nissan
SECTION
EM
GI
MA
LC
EC
CONTENTS
PRECAUTIONS ...............................................................3
Parts Requiring Angular Tightening.............................3
Liquid Gasket Application Procedure ..........................3
PREPARATION ...............................................................4
Special Service Tools ..................................................4
Commercial Service Tools ...........................................5
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .....................................................7
NVH Troubleshooting - Engine Noise .........................8
OUTER COMPONENT PARTS .......................................9
Removal and Installation .............................................9
TIGHTENING PROCEDURES ...................................11
MEASUREMENT OF COMPRESSION PRESSURE ....13
OIL PAN.........................................................................14
Components...............................................................14
Removal.....................................................................14
Installation..................................................................17
TIMING CHAIN ..............................................................21
Components...............................................................21
POSITION FOR APPLYING LIQUID GASKET ............23
Removal.....................................................................24
Inspection...................................................................31
Installation..................................................................31
OIL SEAL.......................................................................39
Replacement..............................................................39
VALVE OIL SEAL .....................................................39
FRONT OIL SEAL ....................................................40
REAR OIL SEAL ......................................................40
CYLINDER HEAD..........................................................42
Components...............................................................42
Removal.....................................................................43
Disassembly...............................................................45
Inspection...................................................................46
CYLINDER HEAD DISTORTION ...............................46
CAMSHAFT VISUAL CHECK ....................................46
CAMSHAFT RUNOUT ..............................................46
CAMSHAFT CAM HEIGHT .......................................46
CAMSHAFT JOURNAL CLEARANCE ........................46
CAMSHAFT END PLAY............................................47
CAMSHAFT SPROCKET RUNOUT ...........................47
Assembly ...................................................................51
Installation..................................................................51
Valve Clearance.........................................................56
CHECKING .............................................................56
ADJUSTING ............................................................58
ENGINE ASSEMBLY.....................................................60
Removal and Installation ...........................................60
REMOVAL ...............................................................61
INSTALLATION........................................................63
CYLINDER BLOCK .......................................................64
Components...............................................................64
Removal and Installation ...........................................65
Disassembly...............................................................65
PISTON, CRANKSHAFT AND OIL JET ......................65
Inspection...................................................................66
PISTON AND PISTON PIN CLEARANCE ..................66
PISTON RING SIDE CLEARANCE ............................66
PISTON RING END GAP..........................................66
CONNECTING ROD BEND AND TORSION ...............67
CYLINDER BLOCK DISTORTION AND WEAR ...........67
PISTON-TO-BORE CLEARANCE ..............................68
CRANKSHAFT.........................................................69
BEARING CLEARANCE ...........................................69
CONNECTING ROD BUSHING CLEARANCE
(SMALL END) ..........................................................72
FLYWHEEL/DRIVE PLATE RUNOUT ........................73
MOVEMENT AMOUNT OF FLYWHEEL (M/T
MODELS) ................................................................73
Assembly ...................................................................74
PISTON ..................................................................74
OIL JET ..................................................................74
CRANKSHAFT.........................................................75
REPLACEMENT OF PILOT BUSHING (M/T) OR
PILOT CONVERTER (A/T)........................................77
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CONTENTS
DRIVE PLATE .........................................................78
SERVICE DATA AND SPECIFICATIONS (SDS) .........79
General Specifications...............................................79
Compression Pressure ..............................................79
Cylinder Head ............................................................79
Valve ..........................................................................80
VALVE ....................................................................80
VALVE CLEARANCE................................................80
VALVE SPRING .......................................................80
VALVE LIFTER ........................................................80
VALVE GUIDE .........................................................82
Valve Seat..................................................................83
Camshaft and Camshaft Bearing ..............................84
Cylinder Block............................................................85
EM-2
(Contd)
PRECAUTIONS
Parts Requiring Angular Tightening
NFEM0001
GI
MA
LC
EC
FE
CL
MT
2.
I
NFEM0002
AT
AX
SU
BR
SEM164F
3.
4.
5.
Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
Assembly should be done within 5 minutes after coating.
Wait at least 30 minutes before refilling engine oil and engine
coolant.
ST
RS
BT
HA
AEM080
SC
EL
IDX
EM-3
PREPARATION
Special Service Tools
NFEM0003
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name
Description
ST0501S000
(
)
Engine stand assembly
1 ST05011000
(
)
Engine stand
2 ST05012000
(
)
Base
NT042
KV10106500
(
)
Engine stand shaft
NT028
KV10117000
(J41262)
Engine sub-attachment
NT373
KV10117001
(
)
Engine sub-attachment
NT372
ST10120000
(J24239-01)
Cylinder head bolt
wrench
NT583
KV10116200
(J26336-A)
Valve spring compressor
1 KV10115900
(J26336-20)
Attachment
NT022
EM-4
PREPARATION
Special Service Tools (Contd)
Tool number
(Kent-Moore No.)
Tool name
Description
GI
(J39386)
Valve oil seal drift
MA
NT024
EM03470000
(J8037)
Piston ring compressor
LC
EC
NT044
ST16610001
(J23907)
Pilot bushing puller
FE
CL
NT045
KV10111100
(J37228)
Seal cutter
AT
AX
NT046
WS39930000
(
Tube presser
MT
SU
BR
NT052
KV10112100
(BT8653-A)
Angle wrench
ST
RS
BT
NT014
NFEM0004
HA
Description
SC
EL
IDX
NT047
EM-5
PREPARATION
Commercial Service Tools (Contd)
Tool number
(Kent-Moore No.)
Tool name
Description
NT048
NT030
(J-43897-18)
(J-43897-12)
Oxygen sensor thread
cleaner
AEM488
Anti-seize lubricant
(Permatex 133AR or
equivalent meeting MIL
specification MIL-A907)
AEM489
EM-6
NFEM0005
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
SEM706G
EM-7
NFEM0005S01
Use the chart below to help you find the cause of the symptom.
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Operating condition of engine
Location of
noise
Top of
engine
Rocker
cover
Cylinder
head
Type of
noise
Before
After
When
warm-up warm-up starting
When
racing
While
driving
Source of
noise
Check item
Reference
page
Ticking or
clicking
Tappet
noise
Valve clearance
Rattle
Camshaft
bearing
noise
Slap or
knock
Piston pin
noise
EM-66,
EM-72
Piston-to-bore clearance
Piston ring side clearPiston slap
ance
noise
Piston ring end gap
Connecting rod bend
and torsion
EM-68,
EM-66,
EM-66,
EM-67
Crankshaft Slap or
pulley
rap
Cylinder
block
(Side of
engine)
Oil pan
Front of
engine
Timing
chain
cover
When
idling
EM-56
Knock
Connecting rod
bearing
noise
Knock
EM-69,
EM-69
Timing
chain and
chain tensioner
noise
EM-31,
EM-21
Tapping or
ticking
Squeaking
or fizzing
Drive belts
(Sticking
Drive belts deflection
or slipping)
Creaking
Front of
engine
Squall
Creak
A: Closely related
B: Related
C: Sometimes related
: Not related
EM-8
Water
pump
noise
MA section
(Checking
Drive
Belts,
ENGINE
MAINTENANCE)
LC section
(Water
Pump
Inspection,
ENGINE
COOLING
SYSTEM)
NFEM0006
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
SEM707GA
1.
2.
3.
4.
5.
6.
7.
8.
Power valve
VIAS control solenoid valve
Fuel tube
Fuel damper
EM-9
9.
10.
11.
12.
Fuel damper
Vacuum tank
Intake manifold
Service port
IDX
SEM708GA
1.
2.
3.
4.
5.
6.
EM-10
7.
8.
9.
TWC (manifold)
Heated oxygen sensor 2 (rear)
(bank 2)
Water outlet
TIGHTENING PROCEDURES
Intake Manifold
I
1.
2.
I
NFEM0006S01
NFEM0006S0101
GI
MA
LC
SEM709G
Fuel Tube
I
1.
2.
NFEM0006S0102
EC
FE
CL
MT
SEM710G
Fuel Damper
NFEM0006S0103
AT
AX
SU
BR
SEM952F
SEM711G
NFEM0006S0105
ST
RS
BT
HA
SC
EL
IDX
EM-11
NFEM0006S0108
SEM712G
NFEM0006S0107
SEM713G
Power Valve
I
NFEM0006S0109
SEM714G
Exhaust Manifold
NFEM0006S0110
JEM802G
JEM803G
EM-12
NFEM0007
Warm up engine.
Turn ignition switch OFF.
Release fuel pressure.
Refer to EC-56, Fuel Pressure Release.
Disconnect ignition coil with power transistor harness
connectors, then remove ignition coils.
Remove all spark plugs.
Remove fuse for fuel injector.
MA
LC
SEM087G
7.
8.
Minimum
98 (1.0, 14)/300
SEM909E
SEM387C
GI
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-13
OIL PAN
Components
Components
NFEM0008
SEM830G
Removal
NFEM0009
CAUTION:
When removing the aluminum oil pan from engine, first
remove the crankshaft position sensor (POS) from the assembly.
Be careful not to damage sensor edges and signal plate teeth.
1. Remove engine undercover.
2. Drain engine oil.
3.
SEM956F
EM-14
OIL PAN
Removal (Contd)
4.
a.
I
I
GI
MA
LC
SEM957F
b.
c.
EC
FE
CL
MT
SEM960F
5.
AT
AX
SU
BR
SEM575GA
6.
ST
RS
BT
HA
SEM716G
SC
EL
IDX
EM-15
OIL PAN
Removal (Contd)
7.
SEM811E
SEM717G
SEM184F
EM-16
OIL PAN
Removal (Contd)
GI
MA
LC
SEM718G
EC
FE
CL
MT
SEM155F
17. Remove O-rings from cylinder block and oil pump body.
AT
AX
SU
BR
SEM819E
Installation
1.
a.
I
I
NFEM0010
ST
RS
BT
HA
MEM108A
b.
Apply sealant to front cover gasket and rear oil seal retainer
gasket.
SC
EL
IDX
SEM964E
EM-17
OIL PAN
Installation (Contd)
c.
I
SEM159F
d.
I
I
e.
f.
I
I
2.
SEM185FA
SEM819E
SEM186F
3.
SEM718G
EM-18
OIL PAN
Installation (Contd)
4.
5.
6.
7.
GI
MA
LC
8.
EC
FE
CL
MT
SEM222FD
AT
AX
SU
BR
SEM958F
b.
I
ST
RS
BT
HA
SEM159F
I
I
SC
EL
IDX
SEM959F
EM-19
OIL PAN
Installation (Contd)
c.
I
I
SEM956F
EM-20
TIMING CHAIN
Components
Components
NFEM0011
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
SEM832GA
EM-21
TIMING CHAIN
Components (Contd)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Slack guide
Crankshaft sprocket
Timing chain tensioner
Intake valve timing control valve
cover
Chain tensioner cover
Mounting bracket
Water hose clamp
Water pump cover
Intake valve timing control valve
cover
EM-22
20.
21.
22.
23.
24.
25.
26.
27.
28.
TIMING CHAIN
Components (Contd)
=NFEM0011S01
Refer
to
Liquid
Gasket
Application
Procedure
PRECAUTIONS, EM-3.
I Before installation, wipe off the protruding sealant.
in
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
SEM720GA
CAUTION:
I After removing timing chain, do not turn crankshaft and
EM-23
TIMING CHAIN
Components (Contd)
I
I
I
I
Removal
1.
2.
3.
4.
5.
6.
I
I
I
I
I
7.
NFEM0012
SEM721G
EM-24
TIMING CHAIN
Removal (Contd)
8.
GI
MA
LC
SEM722G
9.
EC
FE
CL
MT
SEM723G
AT
AX
SU
BR
SEM724G
ST
RS
BT
HA
SEM725G
SC
EL
IDX
SEM831G
EM-25
TIMING CHAIN
Removal (Contd)
13.
14.
15.
16.
SEM750G
18. Set No. 1 piston at TDC on the compression stroke by rotating crankshaft.
SEM727G
Check that intake and exhaust cam nose on No. 1 cylinder are
installed as shown.
If not, turn the crankshaft one revolution (360) and align as
above.
SEM418G
EM-26
TIMING CHAIN
Removal (Contd)
19. Loosen crankshaft pulley bolt. (At this time remove oil pan rear
cover plate and set a suitable tool to ring gear so that crankshaft cannot rotate.)
I Be careful not to damage the signal plate teeth.
GI
MA
LC
EC
FE
CL
MT
SEM965F
AT
AX
SU
BR
SEM915E
ST
RS
BT
HA
SEM728G
EM-27
SC
EL
IDX
TIMING CHAIN
Removal (Contd)
SEM729G
SEM730G
SEM156F
31. Remove timing chain tensioner cover from front timing chain
case.
32. Remove front oil seal from front timing chain case.
Refer to EM-40, FRONT OIL SEAL.
EM-28
TIMING CHAIN
Removal (Contd)
GI
MA
LC
EC
FE
CL
MT
SEM731G
I
a)
I
b)
I
c)
d)
SEM732G
e)
AT
AX
SU
BR
ST
RS
BT
HA
SEM733G
SC
EL
IDX
SEM810G
EM-29
TIMING CHAIN
Removal (Contd)
SEM426G
SEM734G
SEM735G
CAUTION:
I Do not remove plate metal cover of oil passage.
I After removing chain case, do not apply any load which
affects flatness.
KBIA1307E
EM-30
TIMING CHAIN
Removal (Contd)
41. Use a scraper to remove all traces of liquid gasket from front
timing chain case.
GI
MA
LC
SEM737G
Remove old liquid gasket from the bolt hole and thread.
EC
FE
CL
MT
SEM161F
42. Use a scraper to remove all traces of liquid gasket from water
pump cover and intake valve timing control solenoid valve
covers.
AT
AX
SU
BR
SEM926E
Inspection
NFEM0013
ST
RS
BT
HA
SEM928E
Installation
1.
a.
b.
2.
NFEM0014
EM-31
SC
EL
IDX
TIMING CHAIN
Installation (Contd)
3.
I
a.
I
SEM735G
b.
4.
Align rear timing chain case and water pump assembly with
dowel pins (RH and LH) on cylinder block. Then install it.
Do not allow O-ring to drop.
Tighten mounting bolts in order as shown in the figure.
Install two types of mounting bolts, referring to the following
instructions and figure.
Bolt length:
20 mm (0.79 in) (1, 2, 3, 6, 7, 8, 9, and 10 in the figure)
16 mm (0.63 in) (other than the above)
: 12 - 13 Nm (1.2 - 1.4 kg-m, 9 - 10 ft-lb)
After all bolts are temporarily tightened, retighten them to
specified torque in order shown in the figure.
Install chain tension guide.
5.
KBIA1073E
6.
I
SEM929E
EM-32
TIMING CHAIN
Installation (Contd)
SEM430G
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
PBIC0886E
ST
RS
BT
HA
SEM811G
SC
EL
IDX
EM-33
TIMING CHAIN
Installation (Contd)
8.
I
I
SEM739G
9.
I
After confirming the mating marks are aligned, tighten the camshaft sprocket mounting bolts.
Secure the camshaft hexagonal portion using a spanner to
tighten mounting bolts.
SEM426G
10. Pull out the stopper pin from the secondary timing chain tensioner.
SEM810G
EM-34
TIMING CHAIN
Installation (Contd)
GI
MA
LC
EC
FE
CL
MT
SEM740G
AT
AX
SU
BR
SEM741G
ST
RS
BT
HA
SEM733G
15. Install front oil seal to front timing chain case. Refer to EM-40,
FRONT OIL SEAL.
SC
EL
IDX
SEM743G
EM-35
TIMING CHAIN
Installation (Contd)
16. Apply liquid gasket to water pump cover and chain tensioner
cover.
I Before installation, wipe off the protruding sealant.
17. Install water pump cover and chain tensioner cover.
SEM744GA
SEM435G
SEM828G
22. After installing front timing chain case, check surface height
difference between following parts on oil pan mounting surface.
Standard
Front timing chain case to rear timing chain case:
0.14 to 0.14 mm (0.0055 to 0.0055 in)
Oil pump to cylinder block:
0.36 to 0.10 mm (0.0142 to 0.0039 in)
Rear timing chain case to cylinder block:
0.24 to 0.14 mm (0.0094 to 0.0055 in)
SEM746G
EM-36
TIMING CHAIN
Installation (Contd)
GI
MA
LC
23. Install intake valve timing control valve cover.
a. Install new O-rings at front timing chain case.
b. Install new seal ring at intake valve timing control valve cover
with new engine oil applied on it.
c. Apply liquid gasket to intake valve timing control valve covers.
Use genuine RTV silicone sealant or equivalent. Refer to GI-50.
I Being careful not to move the seal ring from the installation
groove, align the dowel pins on the chain case with the holes
to install the intake valve timing control valve cover.
EC
FE
CL
MT
SEM747G
AT
AX
SU
BR
SEM728G
ST
RS
BT
HA
SEM748G
SC
EL
IDX
SEM749G
EM-37
TIMING CHAIN
Installation (Contd)
25. Install intake manifold. Tighten intake manifold nuts and bolts.
Refer to TIGHTENING PROCEDURES, EM-11.
26. Install fuel tube assembly.
Refer to TIGHTENING PROCEDURES, EM-11.
27. Install intake manifold collector gasket.
28. Install intake manifold upper and lower collectors.
Refer to TIGHTENING PROCEDURES, EM-11.
29. Install RH and LH ignition coils.
SEM968F
c.
SEM751G
SEM222FD
EM-38
OIL SEAL
Replacement
Replacement
NFEM0015
CAUTION:
When removing the oil pans, oil pump assembly and timing
chain from engine, first remove the crankshaft position sensor
(POS) from the assembly.
Be careful not to damage sensor edges.
GI
MA
NFEM0015S01
1.
2.
SEM948E
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SEM826E
SC
EL
IDX
SEM827E
EM-39
OIL SEAL
Replacement (Contd)
12. Apply engine oil to new valve oil seal and install it with Tool.
13. Reinstall any parts removed in reverse order of removal.
SEM828E
NFEM0015S03
1.
I
I
I
I
2.
3.
SEM829E
SEM715A
Remove
Remove
Remove
Remove
SEM830E
EM-40
NFEM0015S04
OIL SEAL
Replacement (Contd)
5.
I
GI
MA
LC
6.
I
I
I
EC
FE
CL
MT
SEM832EA
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-41
CYLINDER HEAD
Components
Components
NFEM0043
SEM644G
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Spring
Tensioner sleeve
Valve
Cylinder head
Camshaft position sensor
(PHASE)
13. Spark plug
14. Valve spring seat
EM-42
15.
16.
17.
18.
19.
20.
21.
Valve spring
Valve spring retainer
Valve collet
Valve lifter
Camshaft (Exhaust)
Camshaft (Intake)
Camshaft bracket
CYLINDER HEAD
Components (Contd)
CAUTION:
I When installing camshafts, chain tensioners, oil seals, or
other sliding parts, lubricate contacting surfaces with new
engine oil.
I Apply new engine oil to threads and seat surfaces when
installing cylinder head, camshaft sprocket, crankshaft
pulley, and camshaft bracket.
I Attach tags to valve lifters so as not to mix them up.
GI
MA
LC
Removal
1.
2.
3.
4.
5.
NFEM0044
EC
FE
CL
MT
6.
7.
AT
AX
SU
BR
SEM724G
8.
I
ST
RS
BT
HA
SEM735G
9.
SC
EL
IDX
SEM168FA
EM-43
CYLINDER HEAD
Removal (Contd)
SEM447G
SEM534G
SEM443GA
SEM856E
SEM857E
EM-44
CYLINDER HEAD
Removal (Contd)
GI
MA
LC
SEM444G
EC
FE
CL
MT
SEM859E
AT
AX
SU
BR
SEM860E
ST
RS
BT
HA
SEM863E
Disassembly
NFEM0045
SC
EL
IDX
EM-45
CYLINDER HEAD
Inspection
Inspection
CYLINDER HEAD DISTORTION
SEM861E
NFEM0046
NFEM0046S01
NFEM0046S02
CAMSHAFT RUNOUT
1.
2.
NFEM0046S03
SEM191F
2.
NFEM0046S04
SEM549A
NFEM0046S05
SEM862E
EM-46
CYLINDER HEAD
Inspection (Contd)
3.
4.
SEM012A
GI
MA
LC
EC
FE
CL
MT
NFEM0046S06
AT
AX
SU
BR
SEM864E
3.
NFEM0046S07
ST
RS
BT
HA
SEM865E
NFEM0046S08
SEM178F
EM-47
SC
EL
IDX
CYLINDER HEAD
Inspection (Contd)
2.
a.
b.
c.
SEM938C
NFEM0046S09
1.
2.
3.
4.
SEM008A
SEM931C
SEM932C
5.
SEM950E
EM-48
CYLINDER HEAD
Inspection (Contd)
VALVE SEATS
NFEM0046S10
GI
MA
LC
SEM934C
2.
SEM795A
3.
4.
5.
6.
7.
SEM892B
NFEM0046S11
Bore out old seat until it collapses. Boring should not continue
beyond the bottom face of the seat recess in cylinder head. Set
the machine depth stop to ensure this.
Ream cylinder head recess for service valve seat.
Oversize [0.5 mm (0.020 in)]:
Intake 38.500 - 38.516 mm (1.5157 - 1.5164 in)
Exhaust 32.700 - 32.716 mm (1.2874 - 1.2880 in)
Be sure to ream in circles concentric to the valve guide
center.
This will enable valve seat to fit correctly.
Heat cylinder head to 110 to 130C (230 to 266F) by soaking
in heated oil.
Press fit valve seat until it seats on the bottom.
Cut or grind valve seat using suitable tool to the specified
dimensions as shown in SDS (EM-83).
After cutting, lap valve seat with abrasive compound.
Check valve seating condition.
Seat face angle : 4515 - 4545
Contacting width W:
Intake 1.09 - 1.31 mm (0.0429 - 0.0516 in)
Exhaust 1.29 - 1.51 mm (0.0508 - 0.0594 in)
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
8.
SEM621F
EM-49
SC
EL
IDX
CYLINDER HEAD
Inspection (Contd)
VALVE DIMENSIONS
NFEM0046S12
SEM188A
VALVE SPRING
Squareness
1.
2.
NFEM0046S13
NFEM0046S1301
Measure dimension S.
Out-of-square S:
Less than 2.0 mm (0.079 in)
If it exceeds the limit, replace spring.
SEM288A
Pressure
NFEM0046S1302
VALVE LIFTER
NFEM0046S14
1.
2.
KBIA0182J
JEM798G
EM-50
CYLINDER HEAD
Inspection (Contd)
GI
MA
LC
SEM867E
Assembly
1.
I
I
I
I
NFEM0047
EC
FE
CL
MT
SEM085D
Installation
1.
I
NFEM0048
Before installing rear timing chain case, remove old liquid gasket from mating surface using a scraper.
Also remove old liquid gasket from mating surface of cylinder
block.
AT
AX
SU
BR
SEM891E
Remove old liquid gasket from the bolt hole and thread.
ST
RS
BT
HA
SEM161F
2.
SC
EL
IDX
SEM892E
EM-51
CYLINDER HEAD
Installation (Contd)
3.
I
SEM532G
4.
I
SEM445G
CAUTION:
Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between d1 and d2
exceeds the limit, replace them with new ones.
Limit (d1 - d2):
0.11 mm (0.0043 in)
I Lubricate threads and seat surfaces of the bolts with new
engine oil.
SEM957E
EM-52
CYLINDER HEAD
Installation (Contd)
5.
I
a.
b.
c.
d.
e.
I
GI
MA
LC
SEM877EA
EC
FE
CL
MT
SEM878EA
AT
AX
SU
BR
SEM879EA
6.
ST
RS
BT
HA
SEM444G
7.
I
SC
EL
IDX
KBIA1071E
EM-53
CYLINDER HEAD
Installation (Contd)
INT/EXH
ID mark
Drill mark
M1
M2
INT
RE
Yes
Yes
No
EXH
RE
No
No
Yes
INT
LH
Yes
Yes
No
EXH
LH
No
No
Yes
RH
LH
SEM653F
Position camshaft
RH exhaust camshaft dowel pin at about 10 oclock
LH exhaust camshaft dowel pin at about 2 oclock
8.
SEM533G
I
I
I
I
SEM564G
SEM446G
EM-54
CYLINDER HEAD
Installation (Contd)
Tightening torque
Tightening order
GI
MA
3
SEM885EA
LC
EC
FE
CL
MT
SEM886EA
9.
AT
AX
SU
BR
SEM443GB
ST
RS
BT
HA
SEM534G
SC
EL
IDX
SEM447G
EM-55
CYLINDER HEAD
Installation (Contd)
12. Apply sealant to the hatched portion of rear timing chain case.
Refer to POSITION FOR APPLYING LIQUID GASKET,
EM-23.
I Apply continuous bead of liquid gasket to mating surface of
rear timing chain case.
I Before installation, wipe off the protruding sealant.
13. Align rear timing chain case with dowel pins, then install on
cylinder head and block.
14. Tighten rear chain case bolts.
a. Tighten bolts in numerical order shown in the figure with
smaller torque than specified.
b. Tighten bolts to the specified torque repeating above step a.
15. Reinstall all removed parts in reverse order of removal.
SEM735G
Valve Clearance
CHECKING
SEM727G
NFEM0049
NFEM0049S01
Check that valve lifters on No. 1 cylinder are loose and valve
lifters on No. 4 are tight.
If not, turn crankshaft one revolution (360) and align as above.
SEM418G
EM-56
CYLINDER HEAD
Valve Clearance (Contd)
7.
Crank
position
No. 2
No. 3
GI
No. 4
No. 5
No. 6
INT EXH INT EXH INT EXH INT EXH INT EXH INT EXH
No. 1 TDC
MA
LC
EC
FE
CL
MT
SEM893E
I
I
AT
AX
SU
BR
SEM139D
ST
RS
Valve
No. 1
Crank
position
No. 2
No. 3
No. 4
No. 5
No. 6
INT EXH INT EXH INT EXH INT EXH INT EXH INT EXH
No. 3 TDC
BT
HA
SC
EL
IDX
SEM894E
EM-57
CYLINDER HEAD
Valve Clearance (Contd)
Crank
position
No. 2
No. 3
No. 4
No. 5
No. 6
INT EXH INT EXH INT EXH INT EXH INT EXH INT EXH
q
No. 5 TDC
14. If all valve clearances are within specification, install the following parts. If they are out of specification, adjust the valve
clearances.
I Intake manifold collectors
I RH and LH rocker covers
I All spark plugs
I All ignition coils
SEM958E
ADJUSTING
NFEM0049S02
3.
4.
SEM754G
I
SEM755G
5.
Stamp mark
Starting: 788C
7.88 (0.3102)
Ending: 836C
8.36 (0.3291)
EM-58
CYLINDER HEAD
Valve Clearance (Contd)
6.
7.
8.
9.
Install camshaft.
Rotate crankshaft a few turns by hand.
Confirm that valve clearance is within standard.
After repair, confirm that valve clearance is within standard
with engine warmed-up.
Valve clearance:
GI
MA
Unit: mm (in)
Cold
Intake
Exhaust
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-59
ENGINE ASSEMBLY
Removal and Installation
NFEM0050
SEM844G
1.
2.
3.
LH engine mounting
RH engine mounting
Mounting bracket
4.
5.
6.
7.
8.
WARNING:
I Situate vehicle on a flat and solid surface.
I Place chocks at front and back of rear wheels.
I Do not remove engine until exhaust system has completely cooled off. Otherwise, you may burn yourself
and/or fire may break out in fuel line.
I For safety during subsequent steps, the tension of wires
should be slackened against the engine.
EM-60
ENGINE ASSEMBLY
Removal and Installation (Contd)
GI
MA
LC
EC
FE
CL
MT
REMOVAL
1.
2.
3.
SEM825G
4.
5.
6.
7.
8.
9.
NFEM0050S01
AT
AX
SU
BR
ST
RS
BT
HA
SEM807G
SC
EL
IDX
SEM808G
EM-61
ENGINE ASSEMBLY
Removal and Installation (Contd)
10. Disconnect control rod and support rod from transaxle (M/T
model).
11. Disconnect control cable from transaxle (A/T model).
SEM835E
SEM836EA
SEM837E
SEM972F
EM-62
ENGINE ASSEMBLY
Removal and Installation (Contd)
INSTALLATION
NFEM0050S02
GI
MA
LC
SEM806G
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-63
CYLINDER BLOCK
Components
Components
NFEM0051
SEM809GA
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
EM-64
18.
19.
20.
21.
22.
23.
24.
Piston pin
Connecting rod bearing
Connecting rod
Piston
Top ring
2nd ring
Cylinder block heater (For
Canada)
25. Oil jet
CYLINDER BLOCK
Removal and Installation
SEM180FA
NFEM0052
CAUTION:
I When installing bearings, pistons, or other sliding parts,
lubricate contacting surfaces with new engine oil.
I Place removed parts such as bearings and bearing caps
in their proper order and direction.
I When installing connecting rod nuts, and main bearing
cap bolts, apply new engine oil to threads and seating
surfaces.
I Do not allow any magnetic materials to contact the signal
plate teeth of flywheel or drive plate.
Disassembly
PISTON, CRANKSHAFT AND OIL JET
1.
2.
3.
4.
5.
6.
GI
MA
LC
NFEM0053
NFEM0053S01
EC
FE
CL
MT
SEM190FA
7.
I
AT
AX
SU
BR
SEM965A
9.
I
I
ST
RS
BT
HA
SEM842E
SC
EL
IDX
SEM454G
EM-65
CYLINDER BLOCK
Inspection
Inspection
PISTON AND PISTON PIN CLEARANCE
1.
NFEM0054
NFEM0054S01
AEM023
2.
AEM024
SEM024AA
NFEM0054S02
Side clearance:
Top ring
0.045 - 0.080 mm (0.0018 - 0.0031 in)
2nd ring
0.030 - 0.070 mm (0.0012 - 0.0028 in)
Oil ring
0.065 - 0.135 mm (0.0026 - 0.0053 in)
Max. limit of side clearance:
Top ring 0.11 mm (0.0043 in)
2nd ring 0.1 mm (0.004 in)
If out of specification, replace piston ring. If clearance exceeds
maximum limit with new ring, replace piston.
EM-66
NFEM0054S03
CYLINDER BLOCK
Inspection (Contd)
GI
MA
LC
CONNECTING ROD BEND AND TORSION
NFEM0054S04
Bend:
Limit 0.15 mm (0.0059 in)
per 100 mm (3.94 in) length
Torsion:
Limit 0.30 mm (0.0118 in)
per 100 mm (3.94 in) length
If it exceeds the limit, replace connecting rod assembly.
EC
FE
CL
MT
SEM038F
AT
AX
SU
BR
SEM003F
SEM123C
NFEM0054S05
EM-67
ST
RS
BT
HA
SC
EL
IDX
CYLINDER BLOCK
Inspection (Contd)
PISTON-TO-BORE CLEARANCE
NFEM0054S06
1.
Using a bore gauge, measure cylinder bore for wear, out-ofround and taper.
Cylinder bore inner diameter
Grade No.
No. 1
No. 2
No. 3
Wear limit
SEM843E
2.
SEM321AA
3.
SEM756G
4.
5.
SEM258C
I
6.
7.
EM-68
CYLINDER BLOCK
Inspection (Contd)
CRANKSHAFT
1.
2.
SEM316A
GI
MA
LC
NFEM0054S07
EC
FE
CL
MT
AT
AX
SU
BR
3.
ST
RS
BT
HA
SEM346D
BEARING CLEARANCE
I
NFEM0054S08
Main bearing
1.
NFEM0054S0801
SEM175F
EM-69
SC
EL
IDX
CYLINDER BLOCK
Inspection (Contd)
2.
3.
SEM845E
4.
5.
I
I
AEM033
a.
b.
SEM964
6.
a.
SEM756G
b.
c.
SEM452G
EM-70
CYLINDER BLOCK
Inspection (Contd)
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
SEM845GA
RS
BT
HA
Connecting Rod Bearing (Big end)
1.
2.
3.
NFEM0054S0802
SC
EL
IDX
AEM027
EM-71
CYLINDER BLOCK
Inspection (Contd)
4.
5.
6.
7.
AEM034
8.
SEM452G
0 (Black)
1 (Brown)
2 (Green)
SEM673E
EM-72
CYLINDER BLOCK
Inspection (Contd)
SEM849EB
NFEM0054S10
GI
MA
LC
EC
FE
CL
NOTE:
I Inspection for double mass flywheel only.
I Do not disassemble double mass flywheel.
Flywheel Deflection
I
MT
NFEM0054S1201
AT
AX
SU
BR
I
1.
I
NFEM0054S1202
ST
RS
BT
HA
SC
EL
IDX
EM-73
CYLINDER BLOCK
Inspection (Contd)
2.
3.
4.
I
KBIA0297E
Assembly
PISTON
1.
2.
I
I
I
SEM838F
NFEM0055
NFEM0055S01
SEM757G
SEM160B
OIL JET
1.
I
NFEM0055S02
SEM454G
EM-74
CYLINDER BLOCK
Assembly (Contd)
CRANKSHAFT
1.
I
NFEM0055S03
GI
MA
LC
SEM175F
2.
I
EC
FE
CL
MT
SEM177F
AT
AX
SU
BR
SEM456G
3.
I
I
a)
b)
SEM851E
I
I
I
ST
RS
BT
HA
SC
EL
IDX
EM-75
CYLINDER BLOCK
Assembly (Contd)
4.
5.
Install connecting rod bearings in connecting rods and connecting rod caps.
Confirm that correct bearings are used.
SEM852E
SEM455G
6.
a.
I
I
SEM620
b.
I
I
I
SEM457G
EM-76
CYLINDER BLOCK
Assembly (Contd)
c.
I
I
SEM538G
d.
GI
MA
LC
EC
FE
CL
MT
SEM953E
7.
8.
AT
AX
SU
BR
SEM954E
RS
BT
HA
SEM005G
2.
SC
EL
IDX
SEM163B
EM-77
CYLINDER BLOCK
Assembly (Contd)
DRIVE PLATE
NFEM0055S07
SEM539G
EM-78
General Specifications
Cylinder arrangement
Displacement
cm (cu in)
NFEM0056
GI
V-6
3,498 (213.45)
mm (in)
MA
Valve arrangement
DOHC
Firing order
1-2-3-4-5-6
Compression
Oil
LC
Compression ratio
EC
10.3
Compression Pressure
NFEM0057
Compression pressure
Standard
Minimum
FE
CL
98 (1.0, 14)
MT
AT
Cylinder number
AX
SEM713A
SU
BR
Cylinder Head
NFEM0058
Unit: mm (in)
Standard
Limit
0.1 (0.004)
ST
RS
BT
HA
SC
SEM949E
EL
IDX
EM-79
Valve
NFEM0059
VALVE
NFEM0059S01
Unit: mm (in)
SEM188
Intake
Intake
Exhaust
Intake
Exhaust
Valve length L
4515 - 4545
Exhaust
Intake
Exhaust
Valve margin T
Valve margin T limit
VALVE CLEARANCE
NFEM0059S02
Unit: mm (in)
Cold
Intake
Exhaust
VALVE SPRING
Free height
Pressure
NFEM0059S04
mm (in)
45.62 (1.7961)
Standard
Limit
Out-of-square
mm (in)
VALVE LIFTER
NFEM0059S05
Unit: mm (in)
Valve lifter outer diameter
EM-80
Thickness mm (in)
788C
7.88 (0.3102)
790C
7.90 (0.3110)
792C
7.92 (0.3118)
794C
7.94 (0.3126)
796C
7.96 (0.3134)
798C
7.98 (0.3142)
800C
8.00 (0.3150)
802C
8.02 (0.3157)
804C
8.04 (0.3165)
806C
8.06 (0.3173)
808C
8.08 (0.3181)
810C
8.10 (0.3189)
812C
8.12 (0.3197)
814C
8.14 (0.3205)
816C
8.16 (0.3213)
818C
8.18 (0.3220)
820C
8.20 (0.3228)
822C
8.22 (0.3236)
824C
8.24 (0.3244)
826C
8.26 (0.3252)
828C
8.28 (0.3260)
830C
8.30 (0.3268)
832C
8.32 (0.3276)
834C
8.34 (0.3283)
836C
8.36 (0.3291)
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SEM758G
SC
EL
IDX
EM-81
VALVE GUIDE
NFEM0059S06
Unit: mm (in)
SEM950E
Valve guide
Outer diameter
Valve guide
Standard
Service
Max. tolerance
Intake
0.08 (0.0031)
Exhaust
0.09 (0.0035)
Intake
0.24 (0.0094)
Exhaust
0.28 (0.0110)
EM-82
Valve Seat
NFEM0060
Unit: mm (in)
GI
MA
LC
EC
FE
CL
SEM021EC
MT
AT
AX
SU
BR
SEM621F
Standard
Service
Intake
Exhaust
ST
Exhaust
RS
Exhaust
Intake
Exhaust
BT
HA
Height (h)
Depth (H)
SC
Exhaust
Depth (L)
EL
IDX
EM-83
=NFEM0061
Unit: mm (in)
Standard
Limit
No. 1
0.045 - 0.086 (0.0018 - 0.0034)
No. 2, 3, 4
0.035 - 0.076 (0.0014 - 0.0030)
0.15 (0.0059)
No. 1
26.000 - 26.021 (1.0236 - 1.0244)
No. 2, 3, 4
23.500 - 23.521 (0.9252 - 0.9260)
No. 1
25.935 - 25.955 (1.0211 - 1.0218)
No. 2, 3, 4
23.445 - 23.465 (0.9230 - 0.9238)
0.05 (0.0020)
0.24 (0.0094)
EM671
Cam height A
Intake and
exhaust
0.2 (0.008)
Valve timing
PBIC0187E
Unit: degree
240
238
64
52
EM-84
Cylinder Block
NFEM0062
Unit: mm (in)
GI
MA
LC
SEM022EA
Standard
EC
Surface flatness
Limit
0.10 (0.0039)
Standard
Cylinder bore
Grade No. 1
Grade No. 2
Grade No. 3
Inner diameter
Wear limit
0.20 (0.0079)
Out-of-round (X Y)
Taper (A B C)
Difference in inner
diameter between
cylinders
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
No. A
No. B
No. C
No. D
No. E
No. F
No. G
No. H
No. J
No. K
No. L
No. M
No. N
No. P
No. R
No. S
No. T
No. U
No. V
No. W
No. X
No. Y
No. 4
No. 7
Standard
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-85
NFEM0063
AVAILABLE PISTON
NFEM0063S01
Unit: mm (in)
SEM882E
Grade No. 1
Grade No. 2
Grade No. 3
Standard
a dimension
41.0 (1.614)
Grade No. 0
Grade No. 1
EM-86
PISTON RING
=NFEM0063S02
Unit: mm (in)
Side clearance
End gap
Standard
Limit
Top
0.11 (0.0043)
2nd
0.1 (0.004)
Oil ring
Top
0.54 (0.0213)
2nd
0.80 (0.0315)
0.95 (0.0374)
PISTON PIN
GI
MA
LC
NFEM0063S03
Unit: mm (in)
Grade No. 0
Grade No. 1
FE
EC
CL
0.030 (0.0012)
MT
Connecting Rod
NFEM0064
Unit: mm (in)
Center distance
Limit
0.15 (0.0059)
Limit
0.30 (0.0118)
AT
AX
SU
Grade No. 0
Grade No. 1
Standard
BR
ST
Side clearance
Limit
0.40 (0.0157)
RS
BT
HA
SC
EL
IDX
EM-87
Crankshaft
NFEM0065
Unit: mm (in)
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
Grade
No. A
No. B
No. C
No. D
No. E
No. F
No. G
No. H
No. J
No. K
No. L
No. M
No. N
No. P
No. R
No. S
No. T
No. U
No. V
No. W
No. X
No. Y
No. 4
No. 7
Grade No. 0
Grade No. 1
Grade No. 2
Center distance r
Out-of-round (X Y)
Standard
Taper (A B)
Standard
Runout [TIR*]
Limit
Standard
0.30 (0.0118)
SEM645
EM-88
EM715
NFEM0066
GI
MA
LC
SEM175F
Grade number
Thickness T
Width W
mm (in)
mm (in)
Identification color
(UPR/LWR)
Black
Brown
Green
Yellow
Blue
Pink
Purple
White
UPP
EC
Remarks
FE
CL
Grade is the same for
upper and lower bearings.
MT
AT
AX
01
Brown/Black
LWR
UPR
12
LWR
UPR
19.9 - 20.1
(0.783 - 0.791)
SU
Green/Brown
BR
23
Yellow/Green
LWR
UPR
34
Blue/Yellow
LWR
UPR
ST
RS
45
Pink/Blue
LWR
UPR
BT
56
Purple/Pink
LWR
UPR
HA
67
White/Purple
LWR
SC
UNDERSIZE
NFEM0066S01
Unit: mm (in)
0.25 (0.0098)
Thickness
EM-89
EL
IDX
NFEM0067
NFEM0067S01
Thickness T
mm (in)
Black
Brown
Green
UNDERSIZE
NFEM0067S02
Unit: mm (in)
0.25 (0.0098)
Thickness
Miscellaneous Components
NFEM0068
Unit: mm (in)
Standard
1.3 (0.051)
BEARING CLEARANCE
NFEM0068S01
Unit: mm (in)
Standard
0.065 (0.0026)
Standard
0.070 (0.0028)
EM-90